Apparatus for making dual purpose tiles



Sept. 12, 1967 LQL. woLPA ETAL 3,340,568v

APPARATUS `FOR MAKINQ'DUAL PURPOSE TILES Sheets-*Sheet 1V Filed May 23, 1963 INVENTORS LESTER L. WOL PA WILL/,4M V. Mc/VEELY Sept 12, 1967 L.. woLPA ETAL 3,340,558

` APPARATUS FOR MAKING4 DUAL PURPOSE TILES Filed May 23, 1963 3 Sheets-Sheet 2 INVENTORS LESTER L. WOLP WILL/AM V. Mc /VEELY' BY ,a @Q5 a TToRNEYs l O O N N sept' 12, 1967 L. L ."woLPA TAL APPARATUS FOR MAKING DUAL PURPOSE vTILES 3 Sheets-Sheet 5 Filed May 23, 1963 United States Patent O 3,340,568 APPARATUS FOR MAIiIISN G DUAL PURPOSE TIL Lester L. Wolpa and William V. McNeely, Cincinnati,

Ohio, assignors to Cipco-Cincinnati Industrial Products Company, Cincinnati, Ohio, a corporation of Ohio Filed May 23, 1963, Ser. No. 282,686

4 Claims. (Cl. 18-4) This invention relates to an apparatus for making a dual purpose wall and oor tile product.

A further object of the invention is to provide simple yet highly effective means by which dual purpose tiles having the hereinabove described characteristics may be fabricated.

These and other objects are attained by the means described herein and as disclosed in the accompanying drawings in which:

FIG. 1 is a perspective view of the corner of a room illustrating a floor comprising one surface of the dual purpose tile of the Ipresent invention and two intersecting wall surfaces comprising the other surface of the subject tile.

FIG. 2 is an enlarged plan view of the portion of the upper surface of the tiles -comprising the floor of FIG. l.

FIG. 3 is an enlarged view illustrating the outer surface of the wall-forming tiles of FIG. 1.

FIG. 4 is a sectional View taken on line 4-4 of FIG. 2.

FIG. 5 is a top elevational view of an apparatus for automatically forming, curing and cooling the -dual purpose tiles of the present invention.

FIG. 6 is a side, schematic view of a portion of the apparatus used in automatically forming tiles according to the present invention.

FIG. 7 is a side view of an alternate construction of a portion of the apparatus of FIG. 6.

With particular reference now to FIGS. 1 through 4, the numeral 10 denotes generally a dual purpose tile or panel embodying the teachings ofthe present invention. Each of such tiles comprise a pair of opposed axial faces A and B wherein face A comprises a flat, planar, substantially continuous, load-supporting surface and wherein face B comprises an irregular surface defined by jagged portions 12 of pieces of aggregate 14 which project in random fa-shion from a base in which other portions of the aggregate are iixedly and permanently imbedded.

Uniformly satisfactory results have been obtained in those instances wherein the at face A comprises and is defined by a hardened, rigid, transparent resin 16 in which particles of aggregate are completely imbedded and through which said particles are visible, as in FIG. 2 for producing an Iattractive three-dimensional view of the imbedded aggregate particles imbedded in the transparent resin.

With further reference to FIG. 4, it will be noted that those portions of aggregate 12 which project from the base are completely encapsulated in a hardened, rigid, transparent plastic 20 in the form of a catalyzed resin.

In those instance in which the panels are utilized as a oor, surface B may be received within and secured to a mastic bed; thin set mortar bed or into a full wet bed of mortar, as has heretofore been customary in the art of setting ceramic tile, quarry tile, etc.

In those instances wherein face B is utilized as a wall covering, face A may be securely fastened to a supporting surface by means of suitable adhesives, wherein the individual tiles will be secured to the supporting surface in the manner in which real and/or synthetic tile products are secured for providing wall surfaces.

With reference now to FIG. 6i the numerals 20 denote a plurality of pans or trays each having a bottom and upstanding side walls, said pans being supported between 3,340,568 Patented Sept. 12, 1967 ICC upper reaches C and D of one or more endless support belts or conveyors denoted generally by the numerals 22 and 24. As pans 20 are conveyed from left to right, in FIG. 6 a predetermined quantity of catalyzed resin is deposited onto the bottoms of pans 20 via discharge nozzle 30.

The numeral 40 denotes a mixer unit comprising a motor 42, an impeller lshaft 44 and a screw blade 46 by which a formulated resin is mixed and then pumped through conduit 48 into container 50 by means of a pump 52. The formulated resin within container 50 is conveyed by a conduit 54 to a resin feeding cylinder 56 thence through conduit 58 to a mixing member 60 having a dis-charge port in open communication with nozzle 30 via conduit 62.

The numeral 70 denotes a container or receptacle for a hardener for the formulated .resin of container 50. The contents of container 70 is directed to hardener-feedingcylinder 72 by means of conduit 74, and from the hardener-feeding-cylinder 72 to mixer member 60 via conduit 76.

Each of the feeding cylinders 56 and 72 are operated in timed sequence whereby to convey a predetermined quantity of formulated resin and hardener respectively from containers S0 and 70 to the mixing member 60, and for forcing or expelling the mixture of formulated resin and hardener from mixer 60 through conduit 62, out through nozzle 30 into pans 20.

The present invention is neither directed to nor concerned with the particular means by which the resin feeding cylinder and hardener feeding cylinders 56 and 72 are actuated.

The pans, the bottoms of which are now covered with a predetermined quantity of hardener and formulated resin, are conveyed beneath an aggregate hopper `80 and its associated vibrating feeder pan 82 whereby aggregate will be automatically deposited in the pans and onto the catalyzed resin in the bottoms of the pans.

In the preferred embodiment of the invention pans 20 are subjected to a vibrating `action of a vibrator 84 for compacting the aggregate from hopper 80 and feeder pan 82 into the pan and into the catalyzed resin.

As the -pans continue to advance they are caused to pass beneath feeder pan 92 of aggregate hopper 90 for receiving an additional quantity of aggregate which is deposited onto the aggregate initialy deposited in the pans and onto and into the catalyzed resin.

The pans are again, preferably, subjected to the action of a vibrator 94 for further compacting and densifying the aggregates and/or effectively imbedding said aggregate into the catalyzed resin within the pans.

Thereafter the contents of the pans are subjected to the tamping action of a tamper head 98 which further compacts the aggregates for insuring a substantially uniform overall thickness of the contents of each of the pans. Thereafter the pans are directed through a curing oven O, FIG. 5, for hardening the catalyzed resin for thereby permanently securing the particles of `aggregate to one another an'd t-o the catalyzed resin for completin panels as illustrated in FIGS. 1-4.

In 'the preferred embodiment of the invention the upper surface of the contents of each pan is subjected to a catalyzed resin sprayed thereon immediately after the contents ofV the pan has been subjected to the action of tamper head 98, whereby those upwardly projecting irregular portions of the aggregate which comprise the upper surface of the contents of each of the pans will be completely encapsulated as in FIG. 3 and 4.

With reference now to FIG. 7 a modified form of catalyzed resin applicator has been illustrated for applying a spray of catalyzed resin after tamper 98.

In FIG. 6, the block diagram representing the resin dispenser and generally designated S is shown in a position for spraying the catalyzed resin immediately after the contents of the pan have been tamped, as above described.

Formulated resin from a container 5()` and hardener from a receptacle 70 may be conveyed by gravity through conduits 51 and 71 to regulating valves 53 and 73 respectively thence through open ended conduits 55 and 75 which terminate adjacent and slightly below the discharge end 100 of compressed air conduit 102. The iiow of compressed air through conduit 102 will effectively and automatically deposit catalyzed resin onto the upper surface of the contents of such pans as they leave tamper mechanism at 98.

With particular reference now to FIG. 5, the letter Q denotes generally the loading portion of the apparatus as disclosed, in greater detail in FIG. 6, it being understood that in FIG. 5 only the upper reach of conveyors 22 and 24 of FIG. 6 have been illustrated.

After the individual tile-containing pans 20y have been discharged from conveyor 24 they are transferred to suitable conveyor means for moving said pans, and their contents to the right through an oven O in which the resins are completely and permanently solidified and cured.

The pans containing the now-completed-tiles leaving oven O are then deposited on a conveyor 86 for enabling them to be gradually cooled to ambient temperature.

It should be understood that the present invention is neither directed to nor concerned with the particular structural details of the oven O and/ or cooling chamber C, the illustration of FIG. 5 being exemplary, rather than restrictive, in nature.

From the foregoing it will be noted that there has been disclosed simple and highly effective means for automatically forming, on a mass production basis, dual purpose wall and floor tiles or panels having opposite axial faces, one of which is substantially continuous and smooth as surface A; the other of which is substantially discontinuous and irregular as surface B.

Uniformly satisfactory results have been obtained in those instances wherein the aggregate comprises crushed marble, pea gravel, granite, quartz and the like which have been freed of undesirable lines.

The aggregate contained in hopper 80 is preferably larger in size than the aggregate of the No. 1 hopper 90. The quantity of aggregate applied from hopper No. 1 by means of feeder pan 92 is carefully controlled so that sufficient aggregate is applied to ll any voids occuring in the larger aggregate applied from hopper No. 2 and feeder pan 82.

While the present invention is not limited to the following formula,l excellent and uniformly satisfactory results have been obtained in those instances wherein the formulated resin comprises gallons of No. 31-053 Reichhold polylite polyester resin; 2 gallons rubber grade styrene monomer and 11/2 ounces of 6% cobalt naphthenate.

The foregoing products are thoroughly agitated in mixer 40 and then conveyed to container 50 by means of pump 52.

The hardener contained in receptacle 70 may, by way of example, comprise methyl ethel ketone peroxide. Excellent results have been obtained in those instances in which the hardener is added to the formulated resin at mixer 60 at the rate of approximately 1A; ounce per 10 ounces of resin mix.

In the preferred embodiment of the invention a mold release should be used which allows the rapid mold preparation while assuring adequate releasing properties. Uniformly satisfactory results have been obtained on a commercial basis in those instances wherein a mold release is formulated as follows: 51 ounces toloul (coal tar), 5l ounces mineral spirits VMP, 13 ounces D.D. 130; 13 ounces Partall (Cardis wax). It will be understood that the mold release is applied to the interior of pans 20` and air dried therein prior to the time when they are caused to pass beneath nozzle 30'. The mold release has been found to improve the surface luster of the various products, particularly in those instances wherein the panels being formed will be used with their smooth face, A, uppermost, as in flooring.

The tamping operation at 98 effectively eliminates high spots in the tile product thereby completely eliminating the occurence of bridging when laying the tile.

The heat applied to the products in pans 20 during passage through oven O accelerates the chemical cure and simultaneously dissipates unwanted portions of the resin vehicles which would otherwise produce offensive odors and dimensional instability in the finished product.

Uniformly satisfactory results have been obtained in those instances wherein the product within the pans is maintained in the oven at 200 F. for thirty minutes. Thereafter the now-completed tiles are gradually cooled to ambient temperature over a period of about thirty minutes for relieving stresses in the resin and filler material and precluding the occurences of fractures in the aggregate.

As used herein the term aggregate refers to and includes not only crushed marble, pea gravel, granite, quartz and the like, but also washed and tumbled cullet, metal scrap, wood shavings, and the like.

In those instances wherein the dual purpose tile is to be used exclusively as a wall surface, viz with face B exposed, the ratio of aggregate to resin may be 52 ounces by weight:9.25 liquid ounces by volume.

When the dual purpose tile is to be used only as a floor surface, viz with face A uppermost, the aggregate-resin ratio may be 31.25 ounces by weight:8.50 liquid ounces by volume; and when the tile is to be used as a patio tile uniformly excellent results have been obtained when using 37 ounces by weight of silica to 1l liquid ounces by volume of resin.

It should be understood that various changes and modifications may be made within the scope of the appended claims without departing from the spirit of the invention.

What is claimed is:

j 1. An apparatus for automatically producing dual purpose tile-like products which comprises conveyor means having an upper, pan-supporting reach, means positioned above said reach for uniformly applying a metered quantity of catalyzed resin into each of a plurality of pans supported on said reach, other means positioned above said reach for uniformly applying a metered quantity of aggregate into said pans and onto the resin therein, means adjacent said reach to vibrate the pans for imbedding the aggregate in the resin, other means positioned above said reach for uniformly applying a second metered quantity of aggregate into said pans and onto the contents thereof, means adjacent said reach to vibrate the pans for imbedding the last applied aggregate into the contents of the pans, with portions of the last applied aggregate projecting in random fashion, means for tamping the contents of each pan to dene the maximum amount by which the aggregate particles project from the pan, means applying a uniform coating of catalyzed resin over the projecting portions of all of the last applied aggregate for encapsulating same, means for heating said pans and their contents for effecting a curing and rigidifying of the resin while simultaneously bonding the `aggregate therein, and means for gradually reducing to ambient the temperature of the contents of the pans.

2. Apparatus called for in claim 1, wherein the means for applying said uniform coating of catalyzed resin over the said last applied aggregate includes, in combination, a discharge nozzle, a receptacle for formulated resin, a receptacle for resin hardener, a mixer chamber in open communication with said nozzle, means operative for intermittently feeding predetermined quantities of formulated resin to said mixer chamber, and other means operative for intermittently feeding predetermined quantities of resin hardener to said mixer chamber.

3. Apparatus for producing tile bodies having at least one plane face and formed of a synthetic resin bonded aggregate, said apparatus comprising an endless belt conveyor means having an upper mold pan supporting reach and having a rst end and a second end, shallow mold pans each having a flat bottom and upstanding side walls, said pans being adapted to be supported in tandem upon and conveyed by the said reach of the belt conveyor means from said iirst end toward said second end thereof, nozzle means overlying said rst end of said belt conveyor means for discharging a catalyzed synthetic resin into an underlying mold pan supported upon the belt means, means for supplying a metered quantity of catalyzed resin to said nozzle. means such as to cover the bottom of the said underlying pan, means for driving said conveyor belt means in the direction to move the said reach and carry the pans thereon toward said second end thereof, a irst means for dispensing a metered quantity of aggregate into said pan and onto the resin therein, a vibrator underlying said reach and said irst aggregate dispensing means and acting upon said reach and the pan and contents thereof for vibrating said pan to embed the aggregate in the resin, a second means spaced in the direction of said second end of the belt from said aggregate dispensing means for dispensing a second metered quantity of aggregate into said pan upon the first dispensed aggregate, another vibrating means, said another vibrating means underlying said reach and underlying said second aggregate dispensing means and acting upon said reach and the pan contents for effecting at least partial embedment of the last dispensed aggregate into the rst dispensed aggregate and the resin, means overlying the reach adjacent to the said another vibrating means for tamping the contents of the pan directly following the depositing of the aggregate from said second aggregate depositing means, a second catalyzed tion to apply catalyzed resin over, and following the tamping over, the contents of the pan, and means for effecting curing of the catalyzed resin first introduced into the pan and nally introduced therein over the aggregate therein and the bonding of the aggregate in the resin.

4. The invention according to claim 3, wherein the said second catalyzed resin dispensing means is adapted to apply the resin in the form of a spray.

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WILLIAM I. STEPHENSON, Primary Examiner.

HENRY C. SUTHERLAND, Examiner.

M. O. WARNECKE, Assistant Examiner. 

1. AN APPARATUS FOR AUTOMATICALLY PRODUCING DUAL PURPOSE TILE-LIKE PRODUCTS WHICH COMPRISES CONVEYOR MEANS HAVING AN UPPER, PAN-SUPPORTING REACH, MEANS POSITIONED ABOVE SAID REACH FOR UNIFORMLY APPLYING A METERED QUANTITY OF CATALYZED RESIN INTO EACH OF A PLURALITY OF PANS SUPPORTED ON SAID REACH, OTHER MEANS POSITIONED ABOVE SAID REACH FOR UNIFORMLY APPLYING A METERED QUANTITY OF AGGREGATE INTO SAID PANS AND ONTO THE RESIN THEREIN, MEANS ADJACENT SAID REACH TO VIBRATE THE PANS FOR IMBEDDING THE AGGREGATE IN THE RESIN, OTHER MEANS POSITIONED ABOVE SAID REACH FOR UNIFORMLY APPLYING A SECOND METERED QUANTITY OF AGGREGATE INTO SAID PANS AND ONTO THE CONTENTS THEREOF, MEANS ADJACENT SAID REACH TO VIBRATE THE PANS FOR IMBEDDING THE LAST APPLIED AGGREGATE INTO THE CONTENTS OF THE PANS, WITH PORTIONS OF THE LAST APPLIED AGGREGATE PROJECTING IN RANDOM FASHION, MEANS FOR TAMPING THE CONTENTS OF EACH PAN TO DEFINE THE MAXIMUM AMOUNT BY WHICH THE AGGREGATE PARTICLES PROJECT FROM THE PAN, MEANS APPLYING A UNIFORM COATING OF CATALYZED RESIN OVER THE PROJECTING PORTIONS OF ALL OF THE LAST APPLIED AGGREGATE FOR ENCAPSULATING SAME, MEANS FOR HEATING SAID PANS AND THEIR CONTENTS FOR EFFECTING A CURING AND RIGIDIFYING OF THE RESIN WHILE SIMULTANEOUSLY BONDING THE AGGREGATE THEREIN, AND MEANS FOR GRADUALLY REDUCING TO AMBIENT THE TEMPERATURE OF THE CONTENTS OF THE PANS. 